2001 Lexus ES 300FACTORY OEM SERVICE PROCEDURE

Charging Systems: Reassembly

  1. Install rotor to drive end frame. 
    1. Place the rectifier end frame on the pulley.
    2. Install the rotor to the rectifier end frame.
    Fig 1: Installing Rotor To Drive End Frame
    G03138887Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Install rectifier end frame. 
    1. Place the generator washer on the rotor.
      Fig 2: Placing Generator Washer On Rotor
      G03138888Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a 29 mm socket wrench and press, slowly press in the rectifier end frame.
      Fig 3: Pressing In Rectifier End Frame
      G03138889Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the cord clip with the 4 nuts.
      1. Torque: 
        1. Nut A:  4.5 N.m (46 kgf.cm, 40 in. lbf)
        2. Nut B:  5.4 N.m (55 kgf.cm, 48 in. lbf)
    Fig 4: Identifying Rectifier End Frame Nuts & Cord Clip
    G03138890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Install pulley. 
    1. Install the pulley to the rotor shaft by tightening the pulley nut by hand.
    2. Hold SST (SST 09820-63010-A) with a torque wrench, and tighten SST (SST 09820-63010-B) clockwise to the specified torque.
      1. Torque:  39 N.m (400 kgf.cm, 29 ft. lbf)
    3. Check that SST (SST 09820-63010-A) is secured to the pulley shaft.
      Fig 5: Securing SST 09820-63010-A To Pulley Shaft
      G03138891Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Mount SST (SST 09820-63010-C) in a vise.
    5. Insert SST (SST 09820-63010-B) into SST (SST 09820-63010-C), and attach the pulley nut to SST (SST 09820-63010-C).
      Fig 6: Attaching Pulley Nut To SST 09820-63010-C
      G03138892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. To torque the pulley nut, turn SST (SST 09820-63010-A) in the direction shown. See Fig 7.
      1. Torque:  110.5 N.m (1,125 kgf.cm, 81 ft. lbf)
      Fig 7: Tightening Pulley Nut
      G03138893Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the generator from SST (SST 09820-63010-C).
    8. Turn SST (SST 09820-63010-B), and remove SST (SST 09820-63010-A and SST 09820-63010-B).
    Fig 8: Removing SST 09820-63010-A & SST 09820-63010-B
    G03138894Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Install rectifier holder. 
    1. Place the seal plate on the rectifier end frame.
      Fig 9: Installing Seal Plate On Rectifier End Frame
      G03138895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 4 rubber insulators on the lead wires.
      3. Fig 10: Installing Rubber Insulators On Lead Wires
      G03138896Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the rectifier holder with the 4 screws.
      1. Torque:  2.9 N.m (30 kgf.cm, 26 in. lbf)
    Fig 11: Installing Rectifier Holder
    G03138897Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Install voltage regulator and brush holder. 
    1. Place the voltage regulator and brush holder on the rectifier end frame.
      NOTE: Be careful of the holder installation direction.
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Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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